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YANMAR ENGINE
11
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YANMAR ENGINE SERVICE
CHAPTER 11
YANMAR ENGINE SERVICE
IMPORTANT:
The following is a YANMAR-supplied service manual, modified by
Polaris, to depict the correct service and repair of the 3TMN72-APL.
This manual contains generic repair and maintenance procedures.
Follow all directions and warnings. Do not attempt service of engine
components without proper diesel engine instruction and training.
Component failure from improper repairs may lead to engine failure.
Polaris gratefully acknowledges copyright permissions granted by Yanmar.
11
9923516 - © 2011 Polaris Industries Inc.
11.1
YANMAR ENGINE SERVICE
INTENTIONAL BLANK PAGE
11.2
9923516 - © 2011 Polaris Industries Inc.
TNM Series Service Manual
TNM
series
SERVICE MANUAL
3TNM72
INDUSTRIAL
ENGINES
This Service Manual has been developed for the exclusive use of service and repair
This Service Manual has been developed for the exclusive use of service and repair professionals such as
authorized Distributors and authorized Dealers. It is written with these professionals in mind and may not
contain the necessary detail or safety statements that may be required for a non-professional to perform the
service or repair properly and / or safely. Please contact an authorized repair or service professional before
before working on your engine.
Disclaimers:
All information, illustrations and specifications in this manual are based on the latest information available at
the time of publishing. The illustrations used in this manual are intended as representative reference views
only. Moreover, because of our continuous product improvement policy, we may modify information,
illustrations, and / or specifications to explain and / or exemplify a product, service, or maintenance
improvement. We reserve the right to make any change at any time.
Yanmar and
other countries.
are registered trademarks of Yanmar Co., Ltd. in Japan, the United States and / or
All Rights Reserved:
No part of this publication may be reproduced or used in any form by any means - graphic, electronic, or
mechanical, including photocopying, recording, taping, or information storage and retrieval systems - without
the written permission of Yanmar Co., Ltd. Copyright permission granted to Polaris Industries.
© 2009 Yanmar Co. Ltd.
0709
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TNM Series Service Manual
© 2009 Yanmar Co. Ltd
TABLE OF
CONTENTS
TNM Service Manual
Page
Introduction ......................................................................................... 1-1
Yanmar Warranties.............................................................................. 2-1
Safety.................................................................................................... 3-1
General Service Information .............................................................. 4-1
Periodic Maintenance ......................................................................... 5-1
Engine .................................................................................................. 6-1
Fuel System ......................................................................................... 7-1
Cooling System ................................................................................... 8-1
Lubrication System ............................................................................. 9-1
Starter Motor...................................................................................... 10-1
Alternator ........................................................................................... 11-1
Electric Wiring ................................................................................... 12-1
Troubleshooting ................................................................................ 13-1
TNM Service Manual
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TABLE OF CONTENTS
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iv
TNM Service Manual
© 2009 Yanmar Co. Ltd
TNM Series Service Manual
Section 1
INTRODUCTION
This Service Manual describes the service
procedures for the TNM series indirect injection
engines. These engines are certified by the U.S.
EPA, California ARB and / or the 97/68/EC
Directive for industrial use.
Please use this manual for accurate, quick and safe
servicing of the 3TNM72-APL engine. Since the
directions in this manual are for a typical engine,
some specifications and components may be
different from your engine. Refer to the
documentation supplied by the optional equipment
manufacturer for specific service instructions.
Yanmar products are continuously undergoing
improvement. This Service Manual might not
address possible field modifications to the
equipment.
1-1
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© 2009 Yanmar Co. Ltd
INTRODUCTION
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1-2
TNM Series Service Manual
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TNM Series Service Manual
Section 2
WARRANTY
Page
Emissions Warranty....................................................................... 2-2
2-1
TNM Series Service Manual
© 2009 Yanmar Co. Ltd
n control limited warranty, the term “Manufacturer” means Yanmar Co., Ltd. (Yanmar) as the holder of the U.S.
Environmental Protection Agency (U.S. EPA) Certificate of Conformity and California Executive Order fo r the vehicle.
The emission control limited warranty is in addition to the standard limited warranty for your vehicle.
WARRANTY
Emission System Warranty
EMISSION SYSTEM WARRANTY
6((9(+,&/(2:1(560$18$/)25&203/(7((0,66,216$1'
(1*,1(:$55$17<
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© 2009 Yanmar Co. Ltd
Section 3
TNM Series Service Manual
SAFETY
Page
Safety Statements ........................................................................... 3-3
Safety Precautions .......................................................................... 3-3
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© 2009 Yanmar Co. Ltd
SAFETY
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TNM Series Service Manual
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SAFETY
Safety Statements
12/05
SAFETY STATEMENTS
SAFETY PRECAUTIONS
Polaris is concerned for your safety and your
machine’s condition. Safety statements are one of
the primary ways to call your attention to the
potential hazards associated with Yanmar TNM
engine operation. Follow the precautions listed
throughout the manual before operation, during
operation and during periodic maintenance
procedures for your safety, the safety of others and
to protect the performance of your engine. Keep the
labels from becoming dirty or torn and replace
them if they are lost or damaged. Also, if you need
to replace a part that has a label attached to it,
make sure you order the new part and label at the
same time.
A
This safety alert symbol appears
with most safety statements. It
means attention, become alert,
your safety is involved! Please read
and abide by the message that
follows the safety alert symbol.
Indicates a hazardous situation which, if not
avoided, will result in death or serious injury.
Indicates a hazardous situation which, if not
avoided, could result in death or serious injury.
Indicates a hazardous situation which, if not
avoided, could result in minor or moderate
injury.
The safety messages that follow have DANGER
level hazards.
Crush Hazard
NEVER stand under a hoisted engine.
If the hoist mechanism fails, the engine
will fall on you.
ALWAYS ensure the engine is solidly secured
during service work.
ALWAYS have a helper assist you attach the
engine to a hoist and load it on a truck when you
need to transport the engine for repair.
Exhaust Hazard
NEVER operate the engine in an
enclosed area such as a garage,
tunnel, underground room, manhole or
ship’s hold without proper ventilation.
NEVER block windows, vents or other means of
ventilation if the engine is operating in an enclosed
area. All internal combustion engines create carbon
monoxide gas during operation. Accumulation of
this gas within an enclosure could cause illness or
even death.
ALWAYS make sure that all connections are
tightened to specifications after repair is made to
the exhaust system.
Indicates a situation which can cause damage to
the machine, personal property and / or the
environment, or cause the equipment to operate
improperly.
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© 2009 Yanmar Co. Ltd
SAFETY
Safety Precautions
Entanglement / Sever Hazard
ALWAYS tie back long hair
and keep hands and other
body parts away from
moving / rotating parts such
as the cooling fan, flywheel or PTO shaft.
The safety messages that follow have
WARNING level hazards.
Fire and Explosion Hazard
Diesel fuel is flammable and explosive
under certain conditions.
Refer to Chapter 3 for fuel safety
information.
Before you operate the engine, check for fuel leaks.
If the unit has an electric fuel feed pump, when you
prime the fuel system, turn the key switch to the ON
position for 10 to 15 seconds to allow the electric
fuel feed pump to prime the system.
Only use the key switch to start the engine. NEVER
jump-start the engine. Sparks caused by shorting
the battery to the starter terminals may cause a fire
or explosion.
NEVER use a shop rag to catch diesel fuel. Vapors
from the rag are flammable and explosive.
ALWAYS wear tight-fitting clothing and keep your
hair short or tie it back while the engine is running.
ALWAYS remove all jewelry before you operate or
service the engine.
NEVER start the engine in gear. Sudden movement
of the engine and / or machine could cause death
or serious personal injury.
NEVER operate the engine without the guards in
place.
Before you start the engine, make sure that all
bystanders are clear of the area.
Keep children and pets away while the engine is
operating.
Wipe up any spills immediately.
NEVER use diesel fuel as a cleaning agent.
NEVER wear jewelry, unbuttoned cuffs, ties or
loose-fitting clothing when you are working near
moving / rotating parts such as the flywheel or PTO
shaft.
Check before starting the engine that any tools or
shop rags used during maintenance have been
removed from the area.
NEVER leave the key in the key switch when you
are servicing the engine. Someone may
accidentally start the engine and not realize you are
servicing it.
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© 2009 Yanmar Co. Ltd
Safety Precautions
SAFETY
12/05
Alcohol and Drug Hazard
NEVER operate or service the engine
while you are under the influence of
alcohol or drugs.
Sudden Movement Hazard
Before you start the engine, make sure that all
bystanders are clear of the area.
NEVER operate or service the engine
when you are feeling ill.
Keep children and pets away while the engine is
operating.
NEVER engage the transmission or PTO at an
elevated engine speed.
The safety messages that follow have CAUTION
level hazards.
Flying Object Hazard
ALWAYS wear eye protection when
servicing the engine and when using
compressed air or high-pressure
water. Dust, flying debris, compressed
air, pressurized water or steam may
injure your eyes.
ALWAYS allow the engine to warm up for at least 5
minutes and allow the idle speed of the engine to
return to normal before engaging the transmission
or any PTOs.
Burn Hazard
ALWAYS keep your hands and other
body parts away from hot engine
surfaces such as the muffler, exhaust
pipe, and engine block during
operation and shortly after you shut the engine
down. These surfaces are extremely hot while the
engine is operating and could seriously burn you.
Seek immediate medical attention for burns.
Exposure Hazard
ALWAYS wear personal protective
equipment such as gloves, work
shoes, eye and hearing protection as
required by the task at hand.
The safety messages that follow have NOTICE
level hazards.
If any problem is noted during the visual check, the
necessary corrective action should be taken before
you operate the engine.
If a continuously running engine is operated at
greater than 20° in any direction or if an engine
runs for short periods of time (less than 3 minutes)
at an angle greater than 20° in any direction, the
engine oil may enter the combustion chamber
causing excessive speed and smoke. This may
cause serious engine damage.
NEVER operate the engine while wearing a
headset to listen to music or radio because it will be
difficult to hear any warning signals.
ALWAYS wear safety glasses while servicing the
engine to prevent possible eye injury.
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© 2009 Yanmar Co. Ltd
SAFETY
Safety Precautions
Observe the following environmental operating
conditions to maintain engine performance and
avoid premature engine wear:
• Avoid operating in the presence of chemical
gases or fumes.
• Avoid operating in a corrosive atmosphere such
as salt water spray.
• NEVER operate the engine in a floodplain unless
proper precautions are taken to avoid being
subject to a flood.
• NEVER expose the engine to the rain.
• The standard range of ambient temperatures for
the normal operation of Yanmar engines is from
+5°F (-15°C) to +104°F (+40°C).
• If the ambient temperature exceeds +104°F
(+40°C), the engine may overheat and cause the
engine oil to break down.
• If ambient temperature is between -25°F (-31°C),
and +5°F (-15°C) the engine will be hard to start
and the engine oil may not flow easily. Polaris
recommends the use of a cold start kit.
• Contact your authorized dealer or distributor
if the engine will be operated outside the
standard temperature range.
The illustrations and descriptions of optional
equipment in this manual, such as the operator's
console, are for a typical engine installation. Refer
to the documentation supplied by the optional
equipment manufacturer for specific operation and
maintenance instructions.
If any indicator fails to illuminate when the key
switch is in the ON position, see your authorized
dealer or distributor for service before operating
the engine.
For maximum engine life, Yanmar recommends that
before shutting the engine down, you allow the
engine to idle, without load, for 5 minutes. This will
allow the engine components that operate at high
temperatures, such as the exhaust system, to cool
slightly before the engine is shut down.
T he engine itself may be shut down at that time .
NEVER use an engine starting aid such as ether.
Engine damage will result.
New Engine Break-in:
• On the initial engine start-up, allow the engine to
idle for approximately 15 minutes while you check
for proper engine oil pressure, diesel fuel leaks,
engine oil leaks, coolant leaks, and for proper
operation of the indicators and / or gauges.
• During the first hour of operation, vary the engine
speed and the load on the engine. Short periods
of maximum engine speed and load are
desirable. Avoid prolonged operation at minimum
or maximum engine speeds and loads for the
next 4 to 5 hours.
• During the break-in period, carefully observe the
engine oil pressure and engine temperature.
• During the break-in period, check the engine oil
and coolant levels frequently.
If any indicator illuminates during engine operation,
stop the engine immediately. Determine the cause
and repair the problem before you continue to
operate the engine.
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© 2009 Yanmar Co. Ltd
SAFETY
Safety Precautions
12/05
NEVER attempt to modify the engine’s design or
safety features such as defeating the engine speed
limit control or the fuel injection quantity control.
Failure to comply may impair the engine’s safety
and performance characteristics and shorten the
engine’s life. Any alterations to this engine may
affect the warranty coverage of your engine. See
the Warranty in the owner's manual.
Identify all parts and their location using an
appropriate method. It is important that all parts are
returned to the same position during the
reassembly process.
NEVER attempt to adjust the low or high idle speed
limit screws. This may impair the safety and
performance of the machine and shorten its life. If
adjustment is ever required, contact your
authorized dealer or distributor.
Tampering with limit screws may void warranty.
ALWAYS be environmentally
responsible.
Follow the guidelines of the EPA or
other governmental agencies for the
proper disposal of hazardous materials such as
engine oil, diesel fuel and engine coolant. Consult
the local authorities or reclamation facility.
NEVER dispose of hazardous materials
irresponsibly by dumping them into a sewer, on the
ground, or into ground water or waterways.
Failure to follow these procedures may seriously
harm the environment.
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SAFETY
Safety Precautions
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TNM Series Service Manual
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TNM Series Service Manual
Section 4
GENERAL SERVICE
INFORMATION
Page
Safety Precautions .......................................................................... 4-3
Component Identification................................................................. 4-3
Location of Labels ........................................................................... 4-4
Engine Nameplate (Typical) ...................................................... 4-4
EPA / CARB Emission Control Regulations - USA Only ................. 4-4
Emission Control Labels.................................................................. 4-5
EPA / ARB Labels (Typical)....................................................... 4-5
The 97/68/EC Directive Certified Engines....................................... 4-5
Engine Family.................................................................................. 4-6
Function of Major Engine Components ........................................... 4-7
Function of Cooling System Components ....................................... 4-9
Diesel Fuel ....................................................................................
Diesel Fuel Specifications .......................................................
Filling the Fuel Tank ................................................................
Priming the Fuel System .........................................................
4-10
4-10
4-12
4-13
Engine Oil......................................................................................
Engine Oil Specifications ........................................................
Service Categories ..................................................................
Engine Oil Viscosity.................................................................
Checking Engine Oil ................................................................
Adding Engine Oil....................................................................
Engine Oil Capacity (Typical) ..................................................
4-14
4-14
4-14
4-15
4-15
4-15
4-16
Engine Coolant..............................................................................
Engine Coolant Specifications.................................................
Filling Radiator with Engine Coolant........................................
Engine Coolant Capacity (Typical) ..........................................
4-16
4-16
4-17
4-18
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© 2009 Yanmar Co. Ltd
GENERAL SERVICE INFORMATION
Specifications ................................................................................
Description of Model Number..................................................
Engine Speed Specifications...................................................
Engine General Specifications ................................................
4-19
4-19
4-19
4-20
Principal Engine Specifications ..................................................... 4-21
3TNM72 (EPA Tier 4).............................................................. 4-22
Engine Service Information ........................................................... 4-23
Tightening Torques for Standard Bolts and Nuts .......................... 4-24
Abbreviations and Symbols........................................................... 4-26
Abbreviations........................................................................... 4-26
Symbols................................................................................... 4-26
Unit Conversions ...........................................................................
Unit Prefixes ............................................................................
Units of Length ........................................................................
Units of Volume .......................................................................
Units of Mass...........................................................................
Units of Force ..........................................................................
Units of Torque........................................................................
Units of Pressure.....................................................................
Units of Power .........................................................................
Units of Temperature...............................................................
4-2
4-27
4-27
4-27
4-27
4-27
4-27
4-27
4-27
4-27
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GENERAL SERVICE INFORMATION
Safety Precautions
12/05
SAFETY PRECAUTIONS
Before performing any engine service procedures,
review the Safety section on page 3-1.
COMPONENT IDENTIFICATION
Figure 4-1 shows where major engine components are located. Image is a typical engine representation.
Figure 4-1
(19)
(1)
(20)
(18)
(2)
(3)
(21)
(17)
(22)
(16)
(23)
(15)
(4)
(14)
(24)
(5)
(13)
(6)
(12)
(26)
(7)
(11)
(10)
(25)
(8)
(9)
0006458
Figure 4-1
1 – Coolant Temperature Sensor
2 – Lifting Eye (engine cooling end)
3 – Alternator
4 – V-Belt
5 – Engine Coolant Pump
6 – Fuel Return to Fuel Tank
7 – Crankshaft V-Pulley
8 – Side Filler Port (engine oil)
9 – Drain Plug (engine oil)*
10 – Engine Oil Filter
11 – N/A
12 – N/A
13 – Fuel Inlet
14 – Oil Pressure Switch
15 – Dipstick (engine oil)
16 – Governor Lever
17 – Fuel Injection Pump
18 – Top Filler Port (engine oil)
19 – Intake Manifold
20 – Air Intake Port (from air cleaner)
21 – Lifting Eye (flywheel end)
22 – Rocker Arm Cover
23 – Stop Solenoid
24 – Flywheel
25 – Starter Motor
26 – Exhaust Manifold
* Illustration is for general reference only. Engine oil drain plug location may vary based on oil pan options.
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GENERAL SERVICE INFORMATION
LOCATION OF LABELS
Figure 4-2 shows the location of regulatory
emission control (Figure 4-2, (1)) and engine
nameplate (Figure 4-2, (2)) labels on Yanmar TNM
series engines.
In addition to the engine nameplate, the engine
model and serial numbers are stamped on flat pads
on the left side of the crankcase.
Figure 4-2
(2)
(1)
Location of Labels
EPA / CARB EMISSION
CONTROL REGULATIONS - USA
ONLY
Yanmar TNM engines meet Environmental
Protection Agency (EPA) (U.S. Federal) emission
control standards as well as the California Air
Resources Board (CARB) regulations. Only
engines that conform to CARB regulations can be
sold in the State of California.
0006459
Figure 4-2
Engine Nameplate (Typical)
0003852
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TNM Series Service Manual
© 2009 Yanmar Co. Ltd
Emission Control Labels
GENERAL SERVICE INFORMATION
12/05
EMISSION CONTROL LABELS
Since emission control regulations are being issued
on a global basis, it is necessary to identify with
which regulations a particular engine complies. We
have listed several different types of labels you
might find on your engine.
EPA / ARB Labels (Typical)
THE 97/68/EC DIRECTIVE
CERTIFIED ENGINES
The engines described in this manual have been
certified by the 97/68/EC Directive.
To identify the engines that meet this certification,
the 97/68/EC emission control label is affixed on
the engines.
EMISSION CONTROL INFORMATION
THIS ENGINE COMPLIES WITH U.S. EPA REGULATIONS FOR
NONROAD DIESEL ENGINES.
LOW SULFUR FUEL OR ULTRA LOW SULFUR FUEL ONLY
M. Y.
97/68/EC DIRECTIVE
ENGINE FAMILY :
DISPLACEMENT :
LITERS
ENGINE MODEL :
EMISSION CONTROL SYSTEM :
MM3/STROKE @
kW /
RPM
FUEL RATE :
REFER TO OWNER'S MANUAL FOR MAINTENANCE SPECIFICATIONS AND
ADJUSTMENTS
(97/68/EC)
(EPA)
EMISSION CONTROL INFORMATION
THIS ENGINE COMPLIES WITH U. S. EPA AND CALIFORNIA REGULATIONS
FOR
M. Y. NONROAD/OFF-ROAD DIESEL ENGINES.
LOW SULFUR FUEL OR ULTRA LOW SULFUR FUEL ONLY
ENGINE FAMILY :
DISPLACEMENT :
LITERS
ENGINE MODEL :
EMISSION CONTROL SYSTEM :
FUEL RATE :
MM3/STROKE @
kW /
RPM
REFER TO OWNER'S MANUAL FOR MAINTENANCE SPECIFICATIONS AND
ADJUSTMENTS
(EPA & ARB)
TNM Series Service Manual
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© 2009 Yanmar Co. Ltd
GENERAL SERVICE INFORMATION
Engine Family
ENGINE FAMILY
The EPA / ARB labels and the 97/68/EC label all have an Engine Family field. The following is an
explanation of the Engine Family designation:
8 YDX L 0.78 V
3
N
Method of air aspiration
Number of cylinders
Engine speed specifications
Displacement (liter)
Non-road / Off-road engine
Yanmar Diesel
*2008 (QJLQHModel Year
* 8: 2008
9: 2009
10: 2010, etc.
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TNM Series Service Manual
© 2009 Yanmar Co. Ltd
Function of Major Engine Components
GENERAL SERVICE INFORMATION
12/05
FUNCTION OF MAJOR ENGINE COMPONENTS
Component
Function
The air cleaner prevents airborne contaminants from entering the
engine.
Periodic replacement of the air cleaner filter element is
necessary. See the Periodic Maintenance Schedule on page 5-4
for the replacement frequency.
Air Cleaner
Alternator
The alternator is driven by a V-belt which is powered by the
crankshaft V-pulley. The alternator supplies electricity to the engine
systems and charges the battery while the engine is running.
Dipstick (Engine Oil)
The engine oil dipstick is used to determine the amount of engine
oil in the crankcase.
Electric Fuel Feed Pump
The electric fuel feed pump makes sure there is a constant supply
of diesel fuel to the fuel injection pump. The electric fuel feed pump
is electro-magnetic and runs on 12 VDC. An electric fuel feed pump
may be installed as standard equipment based on engine model
and specification. If an electric fuel feed pump is installed, turn the
key switch to the ON position for 10 to 15 seconds to prime the fuel
system.
Engine Oil Filter
The engine oil filter removes contaminants and sediments from the
engine oil. Periodic replacement of the engine oil filter is necessary.
See thePeriodic Maintenance Schedule on page 5-4 for the
replacement frequency.
Fuel Filter / Water Separator
The fuel filter / water separator removes contaminants, sediments
and water from diesel fuel going to the fuel filter. This is a required
component of the fuel system. This is standard equipment with
every engine. The separator is installed between the fuel pump and
the engine. Periodically drain the water from the fuel filter / water
separator using the drain cock at the bottom of the separator.
Fuel Priming
The fuel system needs to be primed before you start the engine
for the first time, if your run out of fuel, or if fuel system service is
performed. To prime the system, operate the fuel pump for 10-15
seconds until the
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TNM Series Service Manual
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GENERAL SERVICE INFORMATION
Component
Fuel Tank
Side and Top Filler Port
(Engine Oil)
Starter Motor
Function of Major Engine Components
Function
The fuel tank is a reservoir that holds diesel fuel. When fuel leaves
the tank via the fuel pump. it goes to the fuel filter / water
separator. Next, the fuel goes to the fuel .injection pump.
Since fuel is used to keep the fuel injection pump cool and
lubricated, more fuel than necessary enters the injection pump.
When the injection pump pressure reaches a preset value, a relief
valve allows excess fuel to be returned back to the fuel tank.
You can fill the crankcase with engine oil from either the side or
top filler port depending upon which one is most convenient.
Refer to Chapter 2 for oil viscosity and type recommendation.
The starter motor is powered by the battery. When you turn the key
switch in the operator’s console to the START position, the starter
motor engages with the ring gear installed on the flywheel and
starts the flywheel in motion.
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TNM Series Service Manual
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Function of Cooling System Components
GENERAL SERVICE INFORMATION
12/05
FUNCTION OF COOLING SYSTEM COMPONENTS
Component
Function
The TNM engine is liquid-cooled by means of a cooling system. The
cooling system consists of a radiator, radiator cap, electric cooling
fan, engine coolant pump, thermostat, and reserve tank. Note that
all cooling system components are required for proper engine
operation.
Cooling System
Engine Cooling Fan
The cooling fan is driven by an electric motor controlled by a thermostatic relay system.The purpose of the engine cooling fan is to
circulate air through the radiator.
Engine Coolant Pump
The engine coolant pump circulates the engine coolant through the
cylinder block and cylinder head and returns the engine coolant to
the radiator.
Radiator
The radiator acts as a heat exchanger. As the engine coolant
circulates through the cylinder block it absorbs heat. The heat in the
engine coolant is dissipated in the radiator. As the cooling
fan circulates air through the radiator, the heat is transferred to the
air.
Radiator Cap
The radiator cap controls the cooling system pressure. The cooling
system is pressurized to raise the boiling point of the engine
coolant. As the engine coolant temperature rises, the system
pressure and the coolant volume increases. When the pressure
reaches a preset value, the release valve in the radiator cap opens
and the excess engine coolant flows into the reserve tank. As the
engine coolant temperature is reduced, the system pressure and
volume is reduced and the vacuum valve in the radiator cap opens
allowing engine coolant to flow from the reserve tank back into the
radiator.
Reserve Tank
The reserve tank contains the overflow of engine coolant from the
radiator. If you need to add engine coolant to the system, add it to
the reserve tank, not to the radiator.
Thermostat
A thermostat is placed in the cooling system to prevent engine
coolant from circulating into the radiator until the engine coolant
temperature reaches a preset temperature. When the engine is
cold, no engine coolant flows through the radiator. Once the engine
reaches its operating temperature the thermostat opens. By letting
the engine warm up as quickly as possible, the thermostat reduces
engine wear, deposits and emissions.
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TNM Series Service Manual
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GENERAL SERVICE INFORMATION
Diesel Fuel
DIESEL FUEL
Additional Technical Fuel Requirements
Diesel Fuel Specifications
• The fuel cetane number should be equal to 45 or
higher.
NOTICE: Only use diesel fuels recommended by
Yanmar for the best engine performance, to
prevent engine damage and to comply with EPA /
ARB warranty requirements. Only use clean diesel
fuel.
• The sulfur content must not exceed 0.5% by
volume. Less than 0.05% is preferred. Especially
in U.S.A. and Canada, Low Sulfur (300 to 500
ppm (mg/kg) or Ultra Low Sulfur fuel should be
used.
Diesel fuel should comply with the following
specifications. The table lists several worldwide
specifications for diesel fuels.
• Bio-Diesel fuels. See Bio-Diesel Fuels on
page 4-10.
Diesel Fuel Specification
ASTM D975
No. 1D S15, S500
No. 2D S15, S500
EN590:96
ISO 8217 DMX
BS 2869-A1 or A2
JIS K2204 Grade No. 2
KSM-2610
GB252
Location
• NEVER mix kerosene, used engine oil or residual
fuels with the diesel fuel.
USA
• Water and sediment in the fuel should not exceed
0.05% by volume.
European
Union
International
United
Kingdom
Japan
Korea
China
Diesel Fuel Temperature Specification - USA
• Keep the fuel tank and fuel-handling equipment
clean at all times.
• Poor quality fuel can reduce engine performance
and / or cause engine damage.
• Fuel additives are not recommended. Some fuel
additives may cause poor engine performance.
• Ash content not to exceed 0.01% by volume.
• Carbon residue content not to exceed 0.35% by
volume. Less than 0.1% is preferred.
• Total aromatics content should not exceed 35%
by volume. Less than 30% is preferred.
• PAH (polycyclic aromatic hydrocarbons) content
should be below 10% by volume.
• Metal content of Na, Mg, Si and Al should be
equal to or lower than 1 mass ppm. (Test analysis
method JPI-5S-44-95)
• Lubricity: Wear mark of WS1.4 should be Max.
0.018 in. (460 µm) at HFRR test.
4-10
TNM Series Service Manual
© 2009 Yanmar Co. Ltd
GENERAL SERVICE INFORMATION
Diesel Fuel
12/05
Bio-Diesel Fuels
In Europe and in the United States, as well as some
other countries, non-mineral oil based fuel
resources such as RME (Rapeseed Methyl Ester)
and SOME (Soybean Methyl Ester), collectively
known as FAME (Fatty Acid Methyl Esters), are
being used as extenders for mineral oil derived
diesel fuels.
Yanmar approves the use of bio-diesel fuels that do
not exceed a blend of 5% (by volume) of FAME with
95% (by volume) of approved mineral oil derived
diesel fuel. Such bio-diesel fuels are known in the
marketplace as B5 diesel fuels.
These B5 diesel fuels must meet certain
requirements.
1. The bio-fuels must meet the minimum
specifications for the country in which they are
used.
6. The use of bio-diesel fuels that do not comply
with the standards as agreed to by the diesel
engine manufacturers and the diesel fuel
injection equipment manufacturers, or biodiesel fuels that have degraded as per the
precautions and concerns above, may affect
the warranty coverage of your engine.
B6 To B20 Bio-diesel Fuel Blend Usage
B6 to B20 bio-diesel is not approved for this
engine application
Approved Engines
Only the Yanmar TNM engine series listed below
may operate with bio-diesel fuel concentrations up
to B5 for Polaris applications.
• In Europe, bio-diesel fuels must comply with
the European Standard EN14214.
NOTICE: Do not exceed bio-diesel fuel blend
B5 for this Polaris application.
• In the United States, bio-diesel fuels must
comply with the American Standard
ASTM D-6751.
• 3TNM72-APL
2. Bio-fuels should be purchased only from
recognized and authorized diesel fuel suppliers.
Approved Fuel
Precautions and concerns regarding the use of
bio-fuels:
1. Free methanol in FAME may result in corrosion
of aluminum and zinc fuel injection components.
2. Free water in FAME may result in plugging of
fuel filters and increased bacterial growth.
3. High viscosity at low temperatures may result in
fuel delivery problems, injection pump seizures,
and poor injection nozzle spray atomization.
4. FAME may have adverse effects on some
elastomers (seal materials) and may result in
fuel leakage and dilution of the engine
lubricating oil.
NOTICE: Raw pressed vegetable oils are not
considered bio-diesel, and are unacceptable for
use as fuel in any concentration in Yanmar engines.
Bio-diesel fuel blends up to B5 must comply with
the following standards:
• EN14214 (European standard) and/or ASTM D6751 (American standard).
• All applicable engines may operate with biodiesel fuel up to a maximum B5 (5% bio-diesel
blend) concentration.
5. Even bio-diesel fuels that comply with a suitable
standard as delivered, will require additional
care and attention to maintain the quality of the
fuel in the equipment or other fuel tanks. It is
important to maintain a supply of clean, fresh
fuel. Regular flushing of the fuel system,
and / or fuel storage containers, may be
necessary.
4-11
TNM Series Service Manual
© 2009 Yanmar Co. Ltd
GENERAL SERVICE INFORMATION
Diesel Fuel
Filling the Fuel Tank
Operating Conditions with B5 Bio-diesel
Fuel Blends
WARNING! Fire and Explosion Hazard. Diesel
fuel is flammable and explosive under certain
conditions.
Engine Warranty
Damages, performance or service concerns
determined to be caused by the use of
bio-diesel fuel not meeting the specifications
outlined above are not considered to be defects in
material or factory workmanship and are not
covered under warranty. The same applies to
damages or other concerns induced by not
complying with the recommended operating
conditions of Yanmar engines with biodiesel fuel.
• NEVER refuel with the engine running.
• Only fill the fuel tank with diesel fuel. Filling
the fuel tank with gasoline may result in a fire
and will damage the engine.
• Wipe up all spills immediately.
• Keep sparks, open flames or any other form of
ignition (match, cigarette, static electricity
source) well away when refueling.
• NEVER remove the fuel cap while the engine
is running.
• NEVER overfill the fuel tank.
4-12
TNM Series Service Manual
© 2009 Yanmar Co. Ltd
GENERAL SERVICE INFORMATION
Diesel Fuel
12/05
• ALWAYS put the diesel fuel container on the
ground when transferring the diesel fuel from
the pump to the container. Hold the hose
nozzle firmly against the side of the container
while filling it. This prevents static electricity
buildup which could cause sparks and ignite
fuel vapors.
Figure 4-3
(1)
(2)
• Store any containers containing fuel in a wellventilated area, away from any combustibles
or source of ignition.
• NEVER place diesel fuel or other flammable
material such as oil, hay or dried grass close
to the engine during engine operation or
shortly after shutdown.
NOTICE: Replace rubberized fuel hoses every 2
years or every 2000 hours of engine operation,
whichever comes first, even if the engine has been
out of service. Rubberized fuel lines tend to dry out
and become brittle after 2 years or 2000 hours of
engine operation, whichever comes first. Refer to
Chapter 2 for more information.
Note that a typical fuel tank is shown. The fuel tank
on the equipment being serviced may be different.
0000002A
Figure 4-3
Priming the Fuel System
The fuel system needs to be primed under certain
conditions:
• Before starting the engine for the first time
• After running out of fuel and fuel has been added
to the fuel tank
• After fuel system maintenance such as changing
or draining the fuel filter / water separator, or
replacing a fuel system component
To prime the fuel system if an electric fuel feed
pump is installed:
1. Clean the area around the fuel cap
(Figure 4-3, (1)).
2. Remove the fuel cap (Figure 4-3, (1)) from the
fuel tank (Figure 4-3, (2)).
3. Observe the fuel level gauge and stop fueling
when gauge shows the fuel tank is full.
NEVER overfill the fuel tank.
4. Replace the fuel cap and hand-tighten. Overtightening the fuel cap will damage it.
Turn the key to the ON position for 10 to 15
seconds. This will allow the electric fuel feed pump
to prime the fuel system. WARNING! Fire and
Explosion Hazard. NEVER open the air vent
valve while the fuel system is being primed.
NOTICE: NEVER use the starter motor to crank the
engine in order to prime the fuel system. This may
cause the starter motor to overheat and damage
the coils, pinion and / or ring gear.
4-13
TNM Series Service Manual
© 2009 Yanmar Co. Ltd
GENERAL SERVICE INFORMATION
ENGINE OIL
Engine Oil
Note:
Engine Oil Specifications
NOTICE: Only use the engine oil specified. Other
engine oils may affect warranty coverage, cause
internal engine components to seize or shorten
engine life.
NOTICE: NEVER mix different types of engine oil.
This may adversely affect the lubricating properties
of the engine oil.
Use an engine oil that meets or exceeds the
following guidelines and classifications:
1. Be sure the engine oil, engine oil storage
containers and engine oil filling equipment are
free of sediments and water.
2. Change the engine oil after the first 50 hours
of operation and then every 100 hours
thereafter.
3. Select the oil viscosity based on the ambient
temperature where the engine is being
operated. See the SAE Service Grade
Viscosity Chart (Figure 4-5).
4. Yanmar does not recommend the use of
engine oil “additives.”
Service Categories
• API Service Categories CD or higher
• ACEA Service Categories E-3, E-4 and E-5
• JASO Service Category DH-1
Definitions
• API Classification (American Petroleum Institute)
• ACEA Classification (Association des
Constructeurs Européens d'Automobilies)
• JASO (Japanese Automobile Standards
Organization)
4-14
TNM Series Service Manual
© 2009 Yanmar Co. Ltd
GENERAL SERVICE INFORMATION
Engine Oil
12/05
Additional Technical Engine oil
Requirements:
Figure 4-6
(4)
The engine oil must be changed when the Total
Base Number (TBN) has been reduced to 1.0
(mgKOH/g) test method; JIS K-201-5.2-2 (HCI),
ASTM D4739 (HCI).
(5)
Engine Oil Viscosity
Select the appropriate engine oil viscosity based on
the ambient temperature and use the SAE Service
Grade Viscosity Chart in (Figure 4-5).
(1)
Figure 4-5
(4)
(5)
SAE 10W-30
SAE 15W-40
-25°F
(-31°C)
+5°F
(-15°C)
+86°F
(+30°C)
+104°F
(+40°C)
0000005P
Figure 4-5
Checking Engine Oil
(1)
1. Make sure engine is level.
2. Remove dipstick (Figure 4-6, (1)) and wipe with
clean cloth. NOTICE: Prevent dirt and debris
from contaminating the engine oil. Carefully
clean the oil cap / dipstick and the surrounding
area before you remove the cap.
(2)
(3)
0006463
Figure 4-6
3. Fully reinsert dipstick.
Adding Engine Oil
4. Remove dipstick. The oil level should be
between upper (Figure 4-6, (2)) and lower
(Figure 4-6, (3)) lines on the dipstick. NOTICE:
ALWAYS keep the oil level between the upper
and lower lines on the dipstick.
1. Make sure engine is level.
5. Fully reinsert dipstick. NOTICE: NEVER overfill.
Overfilling may result in white exhaust smoke,
engine overspeed or internal damage.
2. Remove oil cap (Figure 4-6, (4)).
3. Add indicated amount of engine oil at the top or
side engine oil filler port (Figure 4-6, (5)).
Note: Either fill location may be used.
4. Wait 3 minutes and check oil level.
5. Add more oil if necessary.
6. Replace oil cap (Figure 4-6, (4)) and
hand-tighten. Over-tightening may damage the
cap.
4-15
TNM Series Service Manual
© 2009 Yanmar Co. Ltd
GENERAL SERVICE INFORMATION
Engine Coolant
Engine Oil Capacity (Typical)
ENGINE COOLANT
Note: These are the engine oil capacities
associated with the 3TNM72-APL oil
pan.
WARNING! Scald Hazard. ALWAYS check the
level of engine coolant by observing the
reserve tank.
Refer to the operation manual provided
by the driven machine manufacturer for
the actual engine oil capacity of your
machine.
The following is the engine oil capacities for
Yanmar 3TNM72-APL engine:
Engine Model
3TNM72-APL
Engine Capacity
Limit / Lower Limit
1.8 qt. (1.70 l)
CAUTION! Coolant Hazard. Wear eye protection
and rubber gloves when you handle Long Life
Coolant (LLC) or extended life engine coolant. If
contact with the eyes or skin should occur,
flush eyes and wash immediately with clean
water.
Engine Coolant Specifications
NOTICE: Only use the engine coolant specified.
Other engine coolants may affect warranty
coverage, cause an internal buildup of rust and
scale and / or shorten engine life.
NOTICE: NEVER mix different types of engine
coolant. This may adversely affect the properties of
the engine coolant.
4-16
TNM Series Service Manual
© 2009 Yanmar Co. Ltd
GENERAL SERVICE INFORMATION
Engine Coolant
12/05
Alternative Engine Coolant
Filling Radiator with Engine Coolant
ONLY use an ethylene glycol or propylene glycol
based conventional coolant.
Fill the radiator and reserve tank as follows. This
procedure is for filling the radiator for the first time
or refilling it after it is flushed. Note that a typical
radiator is illustrated. WARNING! Burn Hazard.
Wait until the engine cools before you drain the
engine coolant. Hot engine coolant may splash
and burn you.
NOTICE:
• ALWAYS use a mix of coolant and water. NEVER
use water only.
• Mix coolant and water per the mixing instructions
on the coolant container.
Figure 4-7
(2)
• Water quality is important to coolant
performance. Yanmar recommends that soft,
distilled or demineralized water be used to mix
with coolants.
(5)
(3)
• NEVER mix Extended or Long Life Coolants and
conventional (green) coolants.
(6)
FULL
LOW
(4)
• NEVER mix different types and / or colors of
extended life coolants.
• Replace the coolant every 2000 engine hours or
once every two (2) years, which ever comes first.
(1)
0000029A
Figure 4-7
1. Check to be sure the radiator drain plug is
installed and tightened or the drain cock
(Figure 4-7, (1)) is closed. Also make sure the
coolant drain plug (Figure 4-8, (1)) in the
cylinder block is installed.
Figure 4-8
(1)
0006464
Figure 4-8
4-17
TNM Series Service Manual
© 2009 Yanmar Co. Ltd
GENERAL SERVICE INFORMATION
2. Clean all dirt and debris surrounding the
radiator cap. NOTICE: Prevent dirt and debris
from contaminating the engine coolant.
Carefully clean the radiator cap and
surrounding area before you remove the cap.
3. Remove the radiator cap (Figure 4-7, (2)) by
turning it counterclockwise about 1/3 of a turn.
WARNING! Scald Hazard. NEVER remove
the radiator cap if the engine is hot. Steam
and hot engine coolant will spray out and
seriously burn you. Allow the engine to cool
down before you attempt to remove the
radiator cap.
Engine Coolant
Engine Coolant Capacity (Typical)
Note: Capacities listed are for engine only
without a radiator. Refer to the operation
manual provided by the driven machine
manufacturer for actual engine coolant
capacity on your machine.
Refer to Chapter 3 for engine coolant capacity and
bleeding procedure for the Yanmar 3TNM72 -APL
engine.
Engine Coolant
Engine Model
Capacity
3TNM72
Refer to Chapter 3
4. Pour the engine coolant slowly into the radiator
until it is even with the lip of the engine coolant
filler port. Make sure that air bubbles do not
develop as you fill the radiator.
5. Reinstall the radiator cap (Figure 4-7, (2)).
Align the tabs on the back of the radiator cap
with the notches on the engine coolant filler
port. Press down and turn the cap clockwise
about 1/3 of a turn. WARNING! Scald Hazard.
ALWAYS tighten the radiator cap securely
after you check the radiator. Steam can
spray out during engine operation if the cap
is loose.
6. Remove the cap of the reserve tank
(Figure 4-7, (3)), and fill it to the LOW (COLD)
mark (Figure 4-7, (4)) with engine coolant.
Reinstall the cap.
7. Check the hose (Figure 4-7, (5)) that connects
the reserve tank (Figure 4-7, (3)) to the
radiator. Be sure it is securely connected and
there are no cracks or damage. If the hose is
damaged, engine coolant will leak out instead
of going into the reserve tank.
8. Run the engine until it is at operating
temperature. Check the level of engine coolant
in the reserve tank. When the engine is running
and the engine coolant is at normal
temperature, the coolant level in the tank should
be at or near the FULL (HOT) mark
(Figure 4-7, (6)). If the engine coolant is not at
the FULL (HOT) mark (Figure 4-7, (6)), add
additional engine coolant to the reserve tank to
bring the level to the FULL (HOT) mark.
4-18
TNM Series Service Manual
© 2009 Yanmar Co. Ltd
GENERAL SERVICE INFORMATION
Specifications
12/05
SPECIFICATIONS
Description of Model Number
3
TNM
72
0
0000
Customer Code
Rated rpm
Cylinder Bore (mm)
Engine Series
No. of Cylinders
When ordering parts or making an inquiry about the engine you are working on, be sure to include the
complete model and serial numbers as shown on the engine nameplate. See Location of Labels on
page 4-4.
4-19
TNM Series Service Manual
© 2009 Yanmar Co. Ltd
GENERAL SERVICE INFORMATION
Specifications
Engine General Specifications
Type
Vertical In-line, Water Cooled, 4-Cycle Diesel Engine
Combustion System
Swirl Chamber (Ball Type)
Starting System
Electric Starting
Cooling System
Radiator
Lubricating System
Forced Lubrication with Trochoid Pump
PTO Position
Flywheel End
Direction of Rotation
Counterclockwise Viewed from Flywheel End
Note: The information described in Principal Engine Specifications is for a “standard” engine. To obtain the
information for the engine installed in your driven machine, please refer to the manual provided by the
driven machine manufacturer. Engine rating conditions are as follows (SAE J1349, ISO 3046/1):
• Atmospheric Condition: Room temperature 77°F (25°C), Atmospheric pressure 29.53 in.Hg (100 kPa, 750
mmHg), Relative humidity 30%
• Fuel Temperature at Fuel Injector Pump Inlet: 104°F (40°C)
• With Cooling Fan, Air Cleaner, Muffler: Yanmar Standard
• After Engine Break-In Period; Output Allowable Deviation: ± 3%
• 1 PS = 0.7355 kW
• 1 hp SAE (Society of Automotive Engineers) = 0.7457 kW
4-20
TNM Series Service Manual
© 2009 Yanmar Co. Ltd
Principal Engine Specifications
GENERAL SERVICE INFORMATION
12/05
PRINCIPAL ENGINE SPECIFICATIONS
This Page Intentionally Left Blank
4-21
TNM Series Service Manual
© 2009 Yanmar Co. Ltd
GENERAL SERVICE INFORMATION
Principal Engine Specifications
3TNM72 (EPA Tier 4)
Engine Model
3TNM72
Version
CL
VM
Type
CH
Combustion System
Ball-Type Swirl Chamber
Aspiration
Natural
No. of Cylinders
3
Bore × Stroke
2.83 x 2.91 in. (72 × 74 mm)
Displacement
Continuous Rated
Output
Max. Rated Output
(Net)
High Idling
VH
Vertical In-line Diesel Engine
55.1 cu in. (0.904 L)
rpm
(min -1)
hp SAE
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kW
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PS
rpm
(min-1)
hp SAE
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3840
PS
rpm
(min -1) ±
25
Engine Weight (Dry)
with Flywheel
Housing*
187 lb (85 kg)
PTO Position
Flywheel End
Direction of Rotation
Counterclockwise Viewed from Flywheel End
Cooling System
Liquid-Cooled with Radiator
Forced Lubrication with Trochoid Pump
Lubricating System
Normal Oil Pressure at
Rated Engine Speed
Normal Oil Pressure at
Low Idle Speed
34.8 - 63.8 psi (0.240 -0.440 MPa, 2.4 - 4.4 kgf/cm 2)
8.5 psi (0.06 MPa, 0.6 kgf/cm 2) or greater
Electric Starting - Starter Motor: DC12V, 1.6 hp (1.2 kW)
$OWHUQDWRU$'&9
Starting System***
Dimensions
(L × W × H)*
Engine Oil Pan
Capacity**
Engine Coolant
Capacity
Standard Cooling
Fan***
Crank / V-pulley
Dia.***
6HH&KDSHWHURIWKH3RODULV5DQJHU'LHVHO6HUYLFH0DQXDO
19.5 x 16.8 x 21.3 in.
(497 × 427 × 542 mm)
4WV
6HH&KDSWHURIWKH3RODULV'LHVHO6HUYLFH0DQXDO
Polaris-Supplied Electric Fan
PPPP
*
**
Engine specifications without radiator
Engine oil capacity for a “Deep Standard” oil pan. Refer to the Operation Manual provided by the driven machine
manufacturer for the actual engine oil capacity of your machine.
*** May vary depending on application
4-22
TNM Series Service Manual
© 2009 Yanmar Co. Ltd
GENERAL SERVICE INFORMATION
Engine Service Information
12/05
ENGINE SERVICE INFORMATION
Inspection Item
Intake / Exhaust Valve Gap
Standard
Limit
0.006 - 0.010 in
(0.15 - 0.25 mm)
-
See Checking and Adjusting Fuel Injection Timing on page 7-16
Fuel Injection Timing
1784 - 1929 psi
(12.3 - 13.3 MPa;
125 - 136 kgf / cm²)
-
3TNM72
470 ± 15 psi
(3.24 ± 0.1MPa;
33 ± 1 kgf / cm²)
370 ± 15 psi
(2.55 ± 0.1 MPa;
26 ± 1 kgf / cm²)
At rated output
41 - 55 psi (0.28 - 0.38 MPa;
2.86 - 3.87 kgf/cm2)
-
When idling
8.5 psi (0.06 MPa;
0.6 kgf/cm2) or greater
-
Valve Opening Temperature
Full Opening Lift
Temperature
157° - 163°F
(70° - 73°C)
0.32 in. (8 mm) or
Above
185°F (85°C)
Fuel Injection Pressure
Compression Pressure at
250 rpm (250 min¯¹)
Lubricating Oil Pressure
Thermostat
4-23
TNM Series Service Manual
© 2009 Yanmar Co. Ltd
GENERAL SERVICE INFORMATION Tightening Torques for Standard Bolts and Nuts
TIGHTENING TORQUES FOR STANDARD BOLTS AND NUTS
Use the correct amount of torque when you tighten the fasteners on the machine. Applying excessive torque
may damage the fastener or component and not enough torque may cause a leak or component failure.
NOTICE: The tightening torque in the Standard Torque Chart (see General Service Information section)
should be applied only to the bolts with a “7” head. (JIS strength classification: 7T)
• Apply 60% torque to bolts that are not listed.
• Apply 80% torque when tightened to aluminum alloy.
Item
Nominal Thread
Diameter
x Pitch
Tightening Torque
M6 x 1.0 mm
87 - 104 in.-lb
(9.8 - 11.8 N·m;
1.0 - 1.2 kgf·m)
M8 x 1.25 mm
200 - 251 in.-lb
(22.6 - 28.4 N·m;
2.3 - 2.9 kgf·m)
M10 x 1.5 mm
33 - 40 ft-lb
(44.1 - 53.9 N·m;
4.5 - 5.5 kgf·m)
M12 x 1.75 mm
58 - 72 ft-lb
(78.4 - 98.0 N·m;
8.0 - 10 kgf·m)
M14 x 1.5 mm
94 - 108 ft-lb
(127.5 - 147.1 N·m;
13 - 15 kgf·m)
M16 x 1.5 mm
159 - 174 ft-lb
(215.7 - 235.4 N·m;
22 - 24 kgf·m)
1/8 mm
87 in.-lb
(9.8 N·m; 1.0 kgf·m)
1/4 mm
173 in.-lb
(19.6 N·m; 2.0 kgf·m)
3/8 mm
22 ft-lb
(29.4 N·m; 3.0 kgf·m)
1/2 mm
43 ft-lb
(58.8 N·m; 6.0 kgf·m)
Hexagon Bolt (7T)
and Nut
PT Plug
4-24
Remarks
Use 80% of the value at left
when the tightening part is
aluminum.
Use 60% of the value at left
for 4T bolts and lock nuts.
TNM Series Service Manual
© 2009 Yanmar Co. Ltd
-
Tightening Torques for Standard Bolts and Nuts GENERAL SERVICE INFORMATION
12/05
Item
Pipe Joint Bolt
Nominal Thread
Diameter
x Pitch
Tightening Torque
M8
112 - 148 in.-lb
(12.7 - 16.7 N·m;
1.3 - 1.7 kgf·m)
M10
173 - 225 in.-lb
(19.6 - 18.734 N·m,;
2.0 - 3.5 kgf·m)
M12
18 - 25 ft-lb
(24.5 - 34.3 N·m;
2.5 - 3.5 kgf·m)
M14
29 - 36 ft-lb
(39.2 - 49.0 N·m;
4.0 - 5.0 kgf·m)
M16
36 - 43 ft-lb
(49.0 - 58.8 N·m;
5.0 - 6.0 kgf·m)
Remarks
-
Note: Torque values shown in this manual are for clean, non-lubricated fasteners unless otherwise
specified.
TNM Series Service Manual
4-25
© 2009 Yanmar Co. Ltd
GENERAL SERVICE INFORMATION
Abbreviations and Symbols
ABBREVIATIONS AND SYMBOLS
Abbreviations
A
AC
ACEA
Ah
API
ARB
ATDC
BTDC
°C
CARB
CCA
cm
cm³
cm³/min
cu. in.
DC
DI
DVA
EPA
ESG
°F
fl oz
fl oz/min
ft
ft-lb
ft·lbf/min
g
gal
gal/hr
GL
hp
hrs
I.D.
IDI
in.
in.Aq
in.Hg
in.-lb
JASO
kg
kgf/cm²
kgf·cm
kgf·m
km
kPa
kW
L
L/hr
lb
ampere
alternating current
Association des Constructeurs
Européens d’Automobilies
ampere-hour
American Petroleum Institute
Air Resources Board
after top dead center
before top dead center
Celsius
California Air Resources Board
cold cranking amp
centimeter
cubic centimeter
cubic centimeter per minute
cubic inch
direct current
direct injection
direct volt adapter
Environmental Protection Agency
electronic speed governor
degree Fahrenheit
fluid ounce (U.S.)
fluid ounce (U.S.) per minute
foot
foot pound*
foot pound force per minute
gram
gallon (U.S.)
gallon (U.S.) per hour
gear lubricant
horsepower (metric)
hours
inside diameter
indirect injection
inch
inches of water
inches of mercury
inch pound**
Japanese Automobile Standards
Organization
kilogram
kilogram force per square centimeter
kilogram force centimeter
kilogram force meter
kilometers
kilopascal
kilowatt
liter
liter per hour
pound
pound-force
pound foot (Tightening Torque)
pound inch (Tightening Torque)
minute
milliliter
millimeter
millimeters cubed stere
millimeters of water
megapascal
millivolt
newton
newton meter
number
outside diameter
ounce
horsepower (Deutsch)
pound per square inch
quart (U.S.)
revolutions per minute
Society of Automotive Engineers
second
short ton (2000 lb)
Total Base Number
top dead center
volt
volt alternating current
volt direct current
watt
Wide-Open Throttle
lbf
lb-ft
lb-in.
min
mL
mm
mm3/st
mmAq
MPa
mV
N
N·m
No.
O.D.
oz
PS
psi
qt
rpm
SAE
sec
t
TBN
TDC
V
V AC
V DC
W
WOT
Symbols
°
+
±
Ω
μ
%
~
angular degree
plus
minus
plus or minus
ohm
micro
percent
approximate
* Work torque such as engine torque
** Work torque such as starter motor torque
4-26
TNM Series Service Manual
© 2009 Yanmar Co. Ltd
Unit Conversions
GENERAL SERVICE INFORMATION
12/05
UNIT CONVERSIONS
Units of Torque
Unit Prefixes
lb-ft
lb-ft
lb-in.
lb-in.
kgf·m
kgf·m
kgf·m
N·m
N·m
N·m
Prefix
mega
kilo
centi
milli
micro
Symbol
M
k
c
m
μ
Power
x 1,000,000
x 1,000
x 0.01
x 0.001
x 0.000001
Units of Length
mile
ft
in.
in.
km
m
cm
mm
x
x
x
x
x
x
x
x
1.6090
0.3050
2.5400
25.4000
0.6210
3.2810
0.3940
0.0394
= km
=m
= cm
= mm
= mile
= ft
= in.
= in.
Units of Volume
gal (U.S.)
qt (U.S.)
cu in.
cu in.
fl oz (U.S.)
fl oz (U.S.)
cm³
cm³
x
x
x
x
x
x
x
x
3.78540
0.94635
0.01639
16.38700
0.02957
29.57000
1.00000
0.03382
=L
=L
=L
= mL
=L
= mL
= mL
= fl oz (U.S.)
Units of Mass
lb
oz
kg
g
x
x
x
x
0.45360
28.35000
2.20500
0.03527
= kg
=g
= lb
= oz
4.4480
0.4536
0.2248
0.1020
2.2050
9.8070
=N
= kgf
= lbf
= kgf
= lbf
=N
Units of Force
lbf
lbf
N
N
kgf
kgf
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
1.3558
0.1383
0.1130
0.0115
7.2330
86.8000
9.8070
0.7376
8.8510
0.1020
= N·m
= kgf·m
= N·m
= kgf·m
= lb-ft
= lb-in.
= N·m
= lb-ft
= lb-in.
= kgf·m
Units of Pressure
psi
psi
psi
bar
bar
bar
kPa
kPa
kPa
kgf/cm²
kgf/cm²
kgf/cm²
in.Hg (60°)
in.Hg (60°)
in.Hg (60°)
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
0.0689
6.8950
0.0703
14.5030
100.0000
29.5300
0.1450
0.0100
0.0102
98.0700
0.9807
14.2200
0.0333
3.3770
0.0344
= bar
= kPa
= kgf/cm²
= psi
= kPa
= in.Hg (60°F)
= psi
= bar
= kgf/cm²
= psi
= bar
= kPa
= bar
= kPa
= kgf/cm²
Units of Power
hp (metric or
PS)
hp (metric or
PS)
hp SAE
hp SAE
kW
kW
x
0.9863201
= hp SAE
x
0.7354988
= kW
x
x
x
x
1.0138697
0.7456999
1.3596216
1.3410221
= hp (metric or PS)
= kW
= hp (metric or PS)
= hp SAE
Units of Temperature
°F = (1.8 x °C) + 32
°C = 0.556 x (°F - 32)
TNM Series Service Manual
4-27
© 2009 Yanmar Co. Ltd
GENERAL SERVICE INFORMATION
Unit Conversions
This Page Intentionally Left Blank
4-28
TNM Series Service Manual
© 2009 Yanmar Co. Ltd
TNM Series Service Manual
Section 5
PERIODIC
MAINTENANCE
Page
Safety Precautions .......................................................................... 5-3
Introduction...................................................................................... 5-3
Precautions .....................................................................................
The Importance of Periodic Maintenance..................................
Performing Periodic Maintenance .............................................
Yanmar Replacement Parts ......................................................
Required EPA / ARB Maintenance - USA Only.........................
Periodic Maintenance Schedule ......................................................
5-3
5-3
5-3
5-3
5-3
5-4
Periodic Maintenance Procedures .................................................. 5-6
After Initial 50 Hours of Operation ............................................. 5-6
Every 50 Hours of Operation ..................................................... 5-9
Every 250 Hours of Operation ................................................. 5-11
Every 500 Hours of Operation ................................................. 5-15
Every 1000 Hours of Operation ............................................... 5-17
Every 1500 Hours of Operation ............................................... 5-19
Every 2000 Hours of Operation ............................................... 5-20
5-1
TNM Series Service Manual
© 2009 Yanmar Co. Ltd
PERIODIC MAINTENANCE
This Page Intentionally Left Blank
5-2
TNM Series Service Manual
© 2009 Yanmar Co. Ltd
PERIODIC MAINTENANCE
Safety Precautions
12/05
SAFETY PRECAUTIONS
Before performing any maintenance procedures,
review the Safety section on page 3-1.
INTRODUCTION
This section of the Service Manual describes the
procedures for proper care and maintenance of the
engine.
Required EPA / ARB Maintenance USA Only
To maintain optimum engine performance and
compliance with the Environmental Protection
Agency (EPA) Regulations Non-road Engines and
the California Air Resources Board (ARB,
California), it is essential that you follow thePeriodic
Maintenance Schedule on page 5-4 and Periodic
Maintenance Procedures on page 5-6.
PRECAUTIONS
The Importance of Periodic
Maintenance
Engine deterioration and wear occurs in proportion
to length of time the engine has been in service and
the conditions the engine is subject to during
operation. Periodic maintenance prevents
unexpected downtime, reduces the number of
accidents due to poor machine performance and
helps extend the life of the engine.
Performing Periodic Maintenance
Perform periodic maintenance procedures in an
open, level area free from traffic. If possible,
perform the procedures indoors to prevent
environmental conditions, such as rain, wind or
snow, from damaging the machine.
5-3
TNM Series Service Manual
© 2009 Yanmar Co. Ltd
PERIODIC MAINTENANCE
Periodic Maintenance Schedule
PERIODIC MAINTENANCE
SCHEDULE
Daily and periodic maintenance is important to
keep the engine in good operating condition. The
following is a summary of maintenance items by
periodic maintenance intervals. Periodic
maintenance intervals vary depending on engine
application, loads, diesel fuel and engine oil used
and are hard to establish definitively. The following
should be treated only as a general guideline.
Establish a periodic maintenance plan according to
the engine application and make sure you perform
the required periodic maintenance at intervals
indicated. CAUTION! Unsafe Operation Hazard.
Failure to follow these guidelines will impair the
engine's safety and performance
characteristics, shorten the engine’s life and
may affect the warranty coverage on your
engine. ConsultGHDOHURUGLVWULEXWRUIRU
assistance when checking items marked with a
z.
NOTICE: It is important to perform daily checks.
Periodic maintenance prevents unexpected
downtime, reduces the number of accidents due to
poor machine performance and helps extend the
life of the engine.
5-4
TNM Series Service Manual
© 2009 Yanmar Co. Ltd
PERIODIC MAINTENANCE
Periodic Maintenance Schedule
12/05
:Check
:Replace
: Contact an authorized Polaris dealer
Periodic Maintenance Interval
System
Cooling
System
Check Item
Daily
Every
50
hours
Every
100
hours
1st
time
2nd
and
after
Every
1000
hours
Every
1500
hours
Every
2000
hours
Check and Refill Engine Coolant
Check and Clean Radiator Fins
Check and Adjust Cooling Pump V-Belt
Drain, Flush and Refill Cooling System with New
Coolant
Cylinder
Head
Every
150
hours
or
every
2 yr.
whichever
comes
first
Adjust Intake / Exhaust Valve Clearance
Lap Intake / Exhaust Valve Seats (if required)
Electrical
Check Indicators
Equipment Check Battery
Engine Oil
Check Engine Oil Level
Drain and Fill Engine OilDQG5HSODFH)LOWHU
Replace Engine Oil Filter
Emission
Control
Warranty
Inspect, Clean and Test Fuel Injectors, if necessary
Fuel
Check and Refill Fuel Tank Level
1st
time
Inspect Crankcase Breather System
Drain Fuel Filter / Water Separator
Check Fuel Filter / Water Separator
Inspect Fuel Filter / Water Separator Lines/Fittings
Replace Fuel Filter / Water Separator
Hoses
Replace Fuel System and Cooling System Hoses
Intake and
Exhaust
Clean or Replace Air Cleaner Element
Complete
Engine
Overall Visual Check Daily
or
every
2 yrs.
Note: These procedures are considered normal maintenance and are performed at the owner’s expense.
5-5
TNM Series Service Manual
© 2009 Yanmar Co. Ltd
PERIODIC MAINTENANCE
Periodic Maintenance Procedures
PERIODIC MAINTENANCE
PROCEDURES
4. Remove the oil filler cap (Figure 5-1, (1)) to
vent the engine crankcase and allow the engine
oil to drain more easily.
After Initial 50 Hours of Operation
5. Position a container under the engine to collect
waste oil.
Figure 5-1
Perform the following maintenance after the initial
50 hours of operation.
(1)
• Replace Engine Oil and Engine Oil Filter
• Check and Adjust Cooling Pump V-Belt
Replace Engine Oil and Engine Oil Filter
WARNING! Burn Hazard. If you must drain the
engine oil while it is still hot, stay clear of the
hot engine oil to avoid being burned.
NOTICE: Only use the engine oil specified. Other
engine oils may affect warranty coverage, cause
internal engine components to seize or shorten
engine life.
(1)
NOTICE: NEVER mix different types of engine oil.
This may adversely affect the lubricating properties
of the engine oil.
NOTICE: Prevent dirt and debris from
contaminating the engine oil. Carefully clean the oil
cap / dipstick and the surrounding area before you
remove the cap.
NOTICE: NEVER overfill. Overfilling may result in
white exhaust smoke, engine overspeed or internal
damage.
The engine oil on a new engine becomes
contaminated from the initial break-in of internal
parts. It is very important that the initial oil and filter
change is performed as scheduled.
Note: The oil drain plug may be in another
location if an optional oil pan is used.
0006469
Figure 5-1
6. Remove the oil drain plug (Figure 5-2, (1)).
Allow oil to drain.
7. After all oil has been drained from the engine,
reinstall the oil drain plug (Figure 5-2, (1)) and
tighten to25 ft-lb (33.8 N·m).
Drain the engine oil as follows:
1. Make sure the engine is level.
2. Start the engine and bring it up to operating
temperature.
3. Stop the engine.
5-6
TNM Series Service Manual
© 2009 Yanmar Co. Ltd
PERIODIC MAINTENANCE
Periodic Maintenance Procedures
12/05
8. Dispose of used oil properly. NOTICE: ALWAYS
be environmentally responsible. Follow the
guidelines of the EPA or other governmental
agencies for the proper disposal of hazardous
materials such as engine oil, diesel fuel and
engine coolant. Consult the local authorities or
reclamation facility. NEVER dispose of
hazardous materials irresponsibly by dumping
them into a sewer, on the ground, or into
ground water or waterways.
Remove the engine oil filter as follows:
1. Turn the engine oil filter (Figure 5-2, (2))
counterclockwise (Figure 5-2, (3)) using a filter
wrench.
Figure 5-2
(2)
4. Add new engine oil to the engine as specified in
Adding Engine Oil on page 4-15. NOTICE:
NEVER overfill the engine with engine oil.
ALWAYS keep the oil level between the upper
and lower lines on the oil cap / dipstick.
Check and Adjust Cooling Pump V-Belt
The V-belt will slip if it does not have the proper
tension. This will prevent the alternator from
generating sufficient power. Also, the engine will
overheat due to the engine coolant pump pulley
slipping. NOTICE: NEVER get any oil on the
belt(s). Oil on the belt causes slipping and
stretching. Replace the belt if damaged.
Check and adjust the V-belt tension (deflection) as
follows:
1. Press the V-belt down with your thumb with a
force of approximately 22 ft-lb (98 N·m,
10 kgf·m) to check the deflection.
There are three positions to check for V-belt
tension (Figure 5-3, (A), (B) and (C)). You can
check the tension at whichever position is the
most accessible. The proper deflection of a used
V-belt at each position is:
(4)
(3)
(1)
Figure 5-3
(B)
0006465
Figure 5-2
2. Clean the engine oil filter mounting face.
3. Lightly coat the gasket on the new oil filter with
clean engine oil. Install the new engine oil filter
manually by turning it clockwise
(Figure 5-2, (3)) until it contacts the mounting
surface. Tighten to 14 to 17 ft-lb (19.6 to 23.5
N·m, 2.0 to 2.4 kgf·m or one additional turn
using the filter wrench.
(C)
(A)
0006466
Figure 5-3
5-7
TNM Series Service Manual
© 2009 Yanmar Co. Ltd
PERIODIC MAINTENANCE
Periodic Maintenance Procedures
Used V-Belt Tension
• “New V-belt” refers to a V-belt which has been
used less than 5 minutes on a running engine.
A
B
C
3/8 - 1/2 in.
(10 - 14 mm)
1/4 - 3/8 in.
(7 - 10 mm)
5/16 - 1/2 in.
(9 - 13 mm)
2. If necessary, adjust the V-belt tension. Loosen
the adjusting bolt (Figure 5-4, (1)) and move
the alternator (Figure 5-4, (2)) with a pry bar
(Figure 5-4, (3)) to tighten the V-belt to the
desired tension. Then tighten the adjusting bolt.
• “Used V-belt” refers to a V-belt which has been
used on a running engine for 5 minutes or
more.
5. Inspect the condition of the used V-belt. There
must be clearance (Figure 5-5, (1)) between
the V-belt and the bottom of the pulley groove. If
there is no clearance (Figure 5-5, (2)) between
the V-belt and the bottom of the pulley groove,
replace the V-belt.
Figure 5-4
6. Install the new V-belt. Refer to the table for
proper tension.
(3)
New V-Belt Tension
A
B
5/16 - 7/16 in. 3/16 - 5/16 in.
(8 - 12 mm)
(5 - 8 mm)
(1)
C
1/4 - 7/16 in.
(7 - 11 mm)
7. After adjusting, run the engine for 5 minutes or
more. Check the tension again using the
specifications for a used V-belt.
(2)
0000653B
Figure 5-4
Used V-Belt Tension
3. Tighten the V-belt to the proper tension. There
must be clearance (Figure 5-5, (1)) between
the V-belt and the bottom of the pulley groove. If
there is no clearance (Figure 5-5, (2)) between
the V-belt and the bottom of the pulley groove,
replace the V-belt.
A
B
C
3/8 - 1/2 in.
(10 - 14 mm)
1/4 - 3/8 in.
(7 - 10 mm)
5/16 - 1/2 in.
(9 - 13 mm)
Figure 5-5
(2)
(1)
0000584
Figure 5-5
4. Check the V-belt for cracks, oil or wear. If any of
these conditions exist, replace the V-belt.
NOTICE: ALWAYS use the specified V-belt.
Using a non-specified V-belt will cause
inadequate charging and shorten the belt life.
5-8
TNM Series Service Manual
© 2009 Yanmar Co. Ltd
PERIODIC MAINTENANCE
Periodic Maintenance Procedures
12/05
Drain the fuel filter / water separator as follows:
Every 50 Hours of Operation
After you complete the initial 50 hour maintenance
procedures, perform the following procedures every
50 hours thereafter.
1. Position an approved container under the fuel
filter / water separator (Figure 5-6, (1)) to
collect the contaminants.
Figure 5-6
• Drain Fuel Filter / Water Separator
• Check Battery
(1)
Drain Fuel Filter / Water Separator
WARNING! Fire and Explosion Hazard. Diesel
fuel is flammable and explosive under certain
conditions.
• When you remove any fuel system component
to perform maintenance (such as changing
the fuel filter), put an approved container
under the opening to catch the fuel.
• NEVER use a shop rag to catch the fuel.
Vapors from the rag are flammable and
explosive. Wipe up any spills immediately.
• NEVER use diesel fuel as a cleaning agent.
WARNING! Exposure Hazard. Wear eye
protection. The fuel system is under pressure
and fuel could spray out when you remove any
fuel system component.
Drain the fuel filter / water separator periodically
to check for contaminants, such as water, etc.
that may be collected in the filter. NEVER wait until
the scheduled periodic maintenance interval, if
contaminants are discovered, to replace the filter.
(2)
© Polaris 2010
Figure 5-6
2. Open the drain petcock (Figure 5-6, (2)).
Allow filter / separator WRGUDLQXQWLOFOHDU
3. Close the drain petcock (Figure 5-6, (2))
once filter / separator draining is complete.
4. Pour the fuel into an approved container and
dispose properly. Hold the bottom of the cup
with a shop towel to prevent fuel from dripping.
Wipe up any spills immediately.
NOTICE: ALWAYS be environmentally
responsible. Follow the guidelines of the EPA or
other governmental agencies for the proper
disposal of hazardous materials such as engine
oil,diesel fuel and engine coolant.
Consult the local authorities or reclamation
facility. NEVER dispose of hazardous materials
irresponsibly by dumping them into a sewer, on
the ground, or into ground water or waterways.
5. Prime the fuel system by running the fuel pump
10-15 secondsE\WXUQLQJWKHNH\21
5-9
TNM Series Service Manual
© 2009 Yanmar Co. Ltd
PERIODIC MAINTENANCE
Periodic Maintenance Procedures
Check Battery
Conventional Battery Level Check
WARNING! Fire and Explosion Hazard.
NOTICE: Use a specialized battery charger to
recharge a battery with a voltage of 8 volts or less.
Booster-starting a battery with a voltage of 8 volts
or less will generate an abnormally high voltage
and destroy electrical equipment. This information
is provided in the event the OEM-supplied
low-maintenance battery was replaced with a
conventional lead-acid battery.
• NEVER check the remaining battery charge by
shorting out the terminals. This will result in a
spark and may cause an explosion or fire. Use
a hydrometer or voltage meeter to check the
remaining battery charge.
• If the electrolyte is frozen, slowly warm the
battery before you recharge it.
• ALWAYS keep the area around the battery
well-ventilated. While the engine is running or
the battery is charging, hydrogen gas is
produced and can be easily ignited.
• ALWAYS keep sparks, open flame and any
other form of ignition away while the engine is
running or battery is charging.
When the amount of fluid nears the lower limit
(Figure 5-7, (1)), fill with distilled water
(Figure 5-7, (2)) so it is at the upper limit
(Figure 5-7, (3)). If operation continues with
insufficient battery fluid, the battery life is
shortened, and the battery may overheat and
explode. During the summer, check the fluid level
more often than specified.
Figure 5-7
WARNING! Burn Hazard.
(3)
• Batteries contain sulfuric acid. NEVER allow
battery fluid to come in contact with clothing,
skin or eyes. Severe burns will result.
• ALWAYS wear safety goggles and protective
clothing when servicing the battery. If battery
fluid contacts the eyes and / or skin,
immediately flush the affected area with a
large amount of clean water and obtain
prompt medical treatment.
If the engine cranking speed is so slow that the
engine does not start, recharge the battery.
(2)
(1)
0000067A
Figure 5-7
(Conventional Lead-Acid Battery)
If the engine still will not start after charging, check
the battery and the engine’s starting system.
If operating the machine where the ambient
temperature could drop to 5°F (-15°C) or less,
remove the battery from the machine at the end of
the day. Store the battery in a warm place until the
next use. This will help start the engine easily at low
ambient temperatures.
NOTICE: Do not reverse the positive (+) and
negative (-) ends of the battery cable. The
alternator diode and stator coil will be damaged.
5-10
TNM Series Service Manual
© 2009 Yanmar Co. Ltd
PERIODIC MAINTENANCE
Periodic Maintenance Procedures
12/05
Figure 5-8
At 50 Hours of Operation (Break-in)
Perform the following break-in maintenance at 50
hours of operation.
• Replace Engine Oil and Engine Oil Filter
Figure 5-8
Every 150 Hours of Operation
Perform the following maintenance every 150 hours
of operation.
• Check and Clean Radiator Fins
• Check and Adjust Cooling Pump V-Belt
• Drain Fuel Filter / Water Separator Element
• Check and Clean Radiator Fins
• Check and Adjust Cooling Pump V-Belt
• Replace Air Cleaner Element
• Replace Fuel Filter / Water Separator Element
Every 100 Hours of Operation
Perform the following maintenance every 100 hours
of operation.
• Replace Engine Oil and Engine Oil Filter
• Drain Fuel Filter / Water Separator Element
• Check and Clean Radiator Fins
5-11
TNM Series Service Manual
© 2009 Yanmar Co. Ltd
PERIODIC MAINTENANCE
Periodic Maintenance Procedures
Replace Engine Oil and Engine Oil Filter
Check and Clean Radiator Fins
WARNING! Burn Hazard. If you must drain the
engine oil while it is still hot, stay clear of the
hot engine oil to avoid being burned.
CAUTION! Flying Object Hazard. ALWAYS wear
eye protection when servicing the engine and
when using compressed air or high-pressure
water. Dust, flying debris, compressed air,
pressurized water or steam may injure your
eyes.
NOTICE: Only use the engine oil specified. Other
engine oils may affect warranty coverage, cause
internal engine components to seize or shorten
engine life.
NOTICE: NEVER mix different types of engine oil.
This may adversely affect the lubricating properties
of the engine oil.
NOTICE: Prevent dirt and debris from
contaminating the engine oil. Carefully clean the oil
cap / dipstick and the surrounding area before you
remove the cap.
NOTICE: NEVER overfill. Overfilling may result in
white exhaust smoke, engine overspeed or internal
damage.
Change the engine oil every 100 hours of operation
after the initial change at 50 hours. Replace the
engine oil filter at the same time. See Replace
Engine Oil and Engine Oil Filter on page 5-6.
NOTICE: NEVER use high-pressure water or
compressed air at greater than 28 psi (193 kPa;
19,686 mmAq) or a wire brush to clean the radiator
fins. Radiator fins damage easily.
Dirt and dust adhering to the radiator fins reduce
the cooling performance, causing overheating.
Make it a rule to check the radiator fins daily and
clean as needed.
Note that a typical radiator is shown in Figure 5-9
for illustrative purposes only.
• Blow off dirt and dust from fins and radiator with
28 psi (0.19 MPa; 2 kgf/cm2) or less of
compressed air (Figure 5-9, (1)). Be careful not
to damage the fins with the compressed air.
• If there is a large amount of contamination on the
fins, apply detergent, thoroughly clean and rinse
with tap water.
Figure 5-9
(1)
FULL
LOW
0000085A
Figure 5-9
5-12
TNM Series Service Manual
© 2009 Yanmar Co. Ltd
PERIODIC MAINTENANCE
Periodic Maintenance Procedures
12/05
Check and Adjust Cooling Pump V-Belt
Replace Air Cleaner Element
Check and adjust the cooling pump V-belt every 250
hours of operation after the initial 50 hour V-belt
maintenance. See Check and Adjust Cooling Pump
V-Belt on page 5-7.
NOTICE: When the engine is operated in dusty
conditions, clean the air cleaner element more
frequently.
Check and Adjust the Governor Lever and
Engine Speed Control
The governor lever and engine speed control
(throttle lever, accelerator pedal etc.), are
connected together by a cable or linkage. If the
cable becomes stretched, or the linkage wears or
loosens, the governor lever may not respond to a
change in the position of the engine speed control.
NOTICE: NEVER force the throttle cable or pedal
to move. This may deform the governor lever or
stretch the cable and cause irregular operation of
the engine speed control.
NOTICE: NEVER operate the engine with the air
cleaner element(s) removed. This may allow
foreign material to enter the engine and damage it.
Note that a typical air cleaner is shown in
Figure 5-11 for illustrative purposes only.
The engine performance is adversely affected
when the air cleaner element is clogged with dust.
Be sure to clean the air filter element periodically.
1. Unlatch and remove the air cleaner cover
(Figure 5-11, (4)).
2. Remove the element (Figure 5-11, (2)).
NOTICE: Refer to Chapter 2 for throttle cable or
linkage adjustment.
5-13
TNM Series Service Manual
© 2009 Yanmar Co. Ltd
PERIODIC MAINTENANCE
Periodic Maintenance Procedures
Figure 5-11
Replace the Fuel Filter / Water Separator
Element
(3)
NOTICE: Polaris recommends that the fuel filter /
water separator element be replaced at 150 hours.
Refer to the element replacement instructions in the
150 hour interval on page 5-15.
(4)
(2)
(1)
0000070P
Figure 5-11
3. Replace the element with a new one if the
element is damaged, excessively dirty or oily.
4. Apply grease to the air filter sealing surface.
5. Clean inside of the air cleaner cover.
6. Install the element into the air cleaner case
(Figure 5-11, (1)).
7. Install the air cleaner cover seal (if removed)
(Figure 5-11, (3)).
8. Latch the air cleaner cover to the case, making
sure the clips are secured (Figure 5-11, (4)).
Figure 5-12
5-14
TNM Series Service Manual
© 2009 Yanmar Co. Ltd
PERIODIC MAINTENANCE
Periodic Maintenance Procedures
12/05
Every 150 Hours of Operation
Perform the following maintenance every 150 hours
of operation.
• Replace Air Cleaner Element
• Replace Fuel Filter / Water Separator
WARNING! Exposure Hazard. Wear eye
protection. The fuel system is under pressure
and fuel could spray out when you remove any
fuel system component.
Replace the fuel filter / water separator at specified
intervals to prevent contaminants from adversely
affecting the diesel fuel flow.
1. Stop the engine and allow it to cool.
Replace Air Cleaner Element
NOTICE: Protect the air cleaner and electric
components from damage when you use steam or
high-pressure water to clean the engine.
2. Position an approved container under the fuel
filter / water separator (Figure 5-13, (1)) to
collect the contaminants.
Figure 5-6
Replace the air cleaner element (Figure 5-11, (2))
every 150 hours even if it is not damaged or dirty.
NOTICE: The maximum air intake restriction, in
terms of differential pressure measurement, must
not exceed 0.90 psi (6.23 kPa; 635 mmAq). Clean
or replace the air cleaner element if the air intake
restriction exceeds the above mentioned value.
(1)
(3)
(2)
When replacing the element, clean the inside of the
air cleaner case (Figure 5-11, (4)).
If the air cleaner is equipped with a double element,
only remove and replace the inner element
(Figure 5-12, (1)) if the engine lacks power or the
dust indicator actuates (if equipped). This is in
addition to replacing the outer element.
3. Open the drain petcock (Figure 5-13, (2)).
Allow filter / separator draining.
Replace Fuel Filter / Water Separator
4. Close the drain petcock (Figure 5-13, (2))
once filter / separator draining is complete.
WARNING! Fire and Explosion Hazard. Diesel
fuel is flammable and explosive under certain
conditions.
• When you remove any fuel system component
to perform maintenance (such as changing
the fuel filter), put an approved container
under the opening to catch the fuel.
• NEVER use a shop rag to catch the fuel.
Vapors from the rag are flammable and
explosive. Wipe up any spills immediately.
© Polaris 2010
Figure 5-13
5. Pour the fuel into an approved container and
dispose properly. Hold the bottom of the cup
with a shop towel to prevent fuel from dripping.
Wipe up any spills immediately.
6. Remove the filter element (Figure 5-13, (3)) by
turning it counter-clockwise (as viewed from the
bottom).
7. Replace the element with a new one by
threading it onto the assembly. Turn the filter an
additional 1/2 to 3/4 turn after gasket contact
with the sealing surface
• NEVER use diesel fuel as a cleaning agent.
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PERIODIC MAINTENANCE
Periodic Maintenance Procedures
Fuel Safety Reminders
WARNING! Fire and Explosion Hazard. Diesel
fuel is flammable and explosive under certain
conditions.
NOTICE: When you remove any fuel system
component to perform maintenance (such as
changing the fuel filter), put an approved container
under the opening to catch the fuel.
NOTICE: NEVER use a shop rag to catch the fuel.
Vapors from the rag are flammable and explosive.
Wipe up any spills immediately.
NOTICE: Wear eye protection. The fuel system is
under pressure and fuel could spray out when you
remove any fuel system component.
NOTICE: ALWAYS be environmentally responsible.
Follow the guidelines of the EPA or other
governmental agencies for the proper disposal of
hazardous materials such as engine oil, diesel
fuel and engine coolant. Consult the local
authorities or reclamation facility. NEVER
dispose of hazardous materials irresponsibly by
dumping them into a sewer, on the ground, or into
ground water or waterways.
Figure 5-14
NOTICE: NEVER use diesel fuel as a cleaning
agent.
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PERIODIC MAINTENANCE
Periodic Maintenance Procedures
12/05
Every 1000 Hours of Operation
Perform the following maintenance every 1000
hours of operation.
• Drain, Flush and Refill Cooling System with
New Coolant
• Adjust Intake / Exhaust Valve Clearance
Drain, Flush and Refill Cooling System with
New Coolant
WARNING! Scald Hazard. ALWAYS check the
level of engine coolant by observing the
reserve tank.
WARNING! Burn Hazard. Wait until the engine
cools before you drain the engine coolant. Hot
engine coolant may splash and burn you.
CAUTION! Exposure Hazard. ALWAYS wear eye
protection and rubber gloves when you handle
coolant. If contact with the eyes or skin should
occur, flush eyes and wash immediately with
clean water.
NOTICE: Only use the engine coolant specified.
Other engine coolants may affect warranty
coverage, cause an internal buildup of rust and
scale, and / or shorten engine life.
NOTICE: NEVER mix different types of engine
coolant. This may adversely affect the properties of
the engine coolant.
Engine coolant contaminated with rust or scale
reduces the cooling effect.
Drain, flush and refill the cooling system with new
coolant every 1000 hours or once a year,
whichever comes first.
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PERIODIC MAINTENANCE
Periodic Maintenance Procedures
1. Allow engine and coolant to cool. WARNING!
Scald Hazard. NEVER remove the radiator
cap if the engine is hot. Steam and hot
engine coolant will spray out and seriously
burn you. Allow the engine to cool down
before you attempt to remove the radiator
cap.
Figure 5-16
2. Remove the radiator cap (Figure 5-15, (1)).
NOTICE: Prevent dirt and debris from
contaminating the engine coolant. Carefully
clean the radiator cap and surrounding area
before you remove the cap.
(1)
3. Remove the drain plug or open the drain cock
(Figure 5-15, (2)) at the lower position of the
radiator and drain the engine coolant.
0006464
Figure 5-16
Figure 5-15
5. After draining the engine coolant, flush the
radiator and engine block to remove any rust,
scale and contaminants. NOTICE: ALWAYS be
environmentally responsible. Follow the
guidelines of the EPA or other governmental
agencies for the proper disposal of hazardous
materials such as engine oil, diesel fuel and
engine coolant. Consult the local authorities or
reclamation facility. NEVER dispose of
hazardous materials irresponsibly by dumping
them into a sewer, on the ground, or into
ground water or waterways.
(1)
FULL
LOW
(2)
0000074A
Figure 5-15
4. Drain the coolant from the engine block.
Remove the coolant drain plug
(Figure 5-16, (1)) from the engine block.
6. Reinstall and tighten the drain plug or close the
drain cock at the radiator. Reinstall and tighten
the engine block drain plug.
7. Fill radiator and engine with engine coolant.
See Filling Radiator with Engine Coolant on
page 4-17. WARNING! Scald Hazard.
ALWAYS tighten the radiator cap securely
after you check the radiator. Steam can
escape during engine operation if the cap is
loose.
Adjust Intake / Exhaust Valve Clearance
Proper adjustment is necessary to maintain the
correct timing for opening and closing the valves.
Improper adjustment will cause the engine to run
noisily, resulting in poor engine performance and
engine damage. See Measuring and Adjusting
Valve Clearance on page 6-30.
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PERIODIC MAINTENANCE
Periodic Maintenance Procedures
12/05
Inspect Crankcase Breather System
Every 1500 Hours of Operation
Perform the following maintenance every 1500
hours of operation.
• Inspect, Clean and Test Fuel Injectors, if
necessary
• Inspect Crankcase Breather System
Inspect, Clean and Test Fuel Injectors
WARNING! Exposure Hazard.
• ALWAYS avoid skin contact with the highpressure diesel fuel spray caused by a fuel
system leak such as a broken fuel injection
line. High-pressure fuel can penetrate your
skin and result in serious injury. If you are
exposed to high-pressure fuel spray, obtain
prompt medical treatment.
Proper operation of the crankcase breather system
is required to maintain the emission requirements
of the engine. The EPA / ARB requires that the
crankcase breather system is inspected every 1500
hours.
The TNM engines use a crankcase breather
system that has a spring-backed diaphragm
(Figure 5-17, (1)) in the valve cover
(Figure 5-17, (2)). When the crankcase pressure
reaches a predetermined value, the diaphragm
opens a passage that allows crankcase fumes to
be routed to the intake manifold.
Figure 5-17
(4)
(3)
(5)
• NEVER check for a fuel leak with your hands.
ALWAYS use a piece of wood or cardboard.
(1)
Proper operation of the fuel injectors is required to
obtain the optimum injection pattern for full engine
performance. The EPA / ARB requires that the fuel
injectors are inspected, cleaned and tested every
1500 hours. See Testing of Fuel Injectors on
page 7-21.
(2)
This procedure is considered normal maintenance
and is performed at the owner’s expense. This
procedure is not covered by the Limited
Warranty.
026965-00X
Figure 5-17
To inspect the diaphragm and spring
(Figure 5-17, (3)):
1. Remove the bolts retaining the diaphragm
cover (Figure 5-17, (4)).
2. Remove the diaphragm cover, spring,
diaphragm plate (Figure 5-17, (5)) and
diaphragm.
3. Inspect the diaphragm for tears. Inspect the
spring for distortion. Replace components if
necessary.
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PERIODIC MAINTENANCE
Periodic Maintenance Procedures
4. Reinstall the diaphragm, diaphragm plate,
spring and diaphragm cover. Tighten the
diaphragm bolts to the specified torque. See
Tightening Torques for Standard Bolts and Nuts
on page 4-24.
NOTICE: Failure of the diaphragm and / or spring
will cause the loss of pressure control and allow
an excessive amount of crankcase fumes to be
routed to the intake manifold. This could result in
excessive deposits in the intake system, high
engine exhaust smoke levels, excessive engine
oil consumption and / or engine run-on due to the
burning of the engine oil.
Every 2000 Hours of Operation
Perform the following maintenance every 2000
hours of operation.
• Check and Replace Fuel Hoses and Engine
Coolant Hoses
• Lap the Intake and Exhaust Valves
Check and Replace Fuel Hoses and Engine
Coolant Hoses
Regularly check the fuel system and engine coolant
system hoses. If they are cracked or degraded,
replace them. Replace the hoses at least every two
years.
NOTICE:
Replace rubberized fuel hoses every two years or
every 2000 hours of engine operation, whichever
comes first, even if the engine has been out of
service. Rubberized fuel lines tend to dry out and
become brittle after two years or 2000 hours of
engine operation, whichever comes first.
Lap the Intake and Exhaust Valves
Adjustment is necessary to maintain proper contact
of the valves and seats. See Inspection of Intake
and Exhaust Valves on page 6-23.
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